2006 US Army StudentGuides Hyex Student Guide 56p

7/27/2019 2006 US Army StudentGuides Hyex Student Guide 56p

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STUDENT GUIDE

FOR

HYDRAULIC EXCAVATOR

HYEX 230LCR

AND ATTACHMENTS

September 2006


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PREFACE

The purpose of this handout is to provide guidance and knowledge on how to identify the capabilities,

characteristics, major components, attachments, cab controls and instruments on the hydraulic excavator.Within this handout are chapters covering proper procedures for starting and stopping, performing hand

and arm signals, safety requirements, how to perform operators maintenance, maneuvering, lifting loads,

how to replace attachments, ditching and loading haul units.


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TABLE OF CONTENTS

CHAPTER TITLE PAGE

Chapter 1 Introduction to the Hydraulic Excavator 1-1

Chapter 2 Hand and Arm signals 2-1

Chapter 3 Safety Requirements 3-1

Chapter 4 Preventive Maintenance Checks and Services 4-1

Chapter 5 Maneuvering 5-1

Chapter 6 Lifting 6-1

Chapter 7 Attachments 7-1

Chapter 8 Ditching 8-1

Chapter 9 Loading 9-1

Appendix A Performance Evaluation Sheets A-1


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Chapter 1

Introduction to the Hydraulic Excavator

1-1

1. Purpose of the hydraulic excavator: To perform small to large excavation of undisturbed and compacted

soil, loading trucks and rail cars from stockpiles and slots, unit also handles irregular objects using thethumb attachment, capable of lifting and moving small to medium loads.

2. Terms and definitions

a. CurlTo rotate the bucket

b. Work CycleA complete set of operations performed before repeating them

c. DemolitionDestruction or scrapping

d. Break Over PointThe point where the machine is going to tip in front or back

e. ShieldingTemporary bracing to hold sides of excavation from caving in

f. SpoilsWaste material from the dig site

g. Mud PadsWood used to support the machine in unsuitable soil

h. Load ChartA decal located on the machine that shows the lifting capacity

i. SlopingThe sides of an excavation that are laid back so that it wont collapse

Note: While moving in off road terrain, avoid unnecessary damage to waterways or vegetation.

3. Characteristics

a. John Deere model 230LC (civilian), 230LCR (military)

b. Self-propelled track mounted hydraulically activated excavator

c. Weight of excavator is 54,480 lbs.

d. Height of the excavator is 10' 2".

e. Length of the excavator is 46' fully extended.

f. The 230LCR is mostly used for ditching, large excavations, pipe handling, haul unit loading, and

other earth moving operations.

4. Capabilities

a. Hydraulic Thumb


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b. Hydraulically activated

c. Ditching Bucket

1) Capacity - 1.77 cubic yards

2) Weight - 2300 lbs

d. General Purpose Bucket

1) Capacity - 1.63 cubic yards

2) Weight - 2950 lbs

e. Hydraulic hose

1) 50 ft. in length

2) Quick connect couplers

f. Vandal Guards

1) Security

2) Severe weather damage

g. Lifting Capacities:

1) 360 degree Maximum lift 29,580 lbs

2) Lift depends on boom and arm length

h. Operates over adverse terrain.

i. Max slopes of 35 degrees

j. Can operate on rough ground due to its ground clearance of 3' 7".

k. Can operate on soft ground due to its low bearing pressure of 5.13 psi and wide tracks of 32".


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5. Limitations

a. Crossing paved roads, roads must be shored prior to crossing to prevent damage (plywood, tires, etc).

b. If moving the excavator long distances (about 1 mile), it must transported.

c. Top speed at full throttle (rabbit) is 3.4 mph and low throttle (turtle) is 2.2 mph.

6. Major Components

a. Boom assembly

b. Boom cylinder

c. Dipper arm

d. Dipper cylinder

e. Bucket assembly

f. Hydraulic quick latch

g. Lift point

h. Remote lube point

i. Track assembly - 32" wide for lower ground bearing pressure.

NOTES


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7. Operator's Station

a. Control Lever Patterns (Refer to illustration)

A - Arm OutB - Arm In

C - Swing Left

D - Swing RightE - Boom Down

F - Boom Up

G - Bucket LoadH - Bucket Dump

IMPORTANT: Prevent possible machine damage. When digging, avoid

contacting tracks with boom cylinders or buckets.

When digging over the end of the tracks, propel motors should be at the

rear to minimize chain and sprocket wear and to maximize machine

stability and lift capacities.

NOTE: With this control pattern, functions must correspond to the

black-on-white labels located on the control console.

When a lever is released, it will return to neutral. The machine will

stay positioned.

NOTES

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a. Propel levers and pedals

b. Thumb

c. Operator's seat

d. Left control lever and horn

e. Travel alarm and travel alarm cancel

f. Right control lever and power boost

8. Right Front Panel & Right Console Panel (refer to illustration)

A Monitor Panel

B Switch Panel

C Ash Tray

D Cigar Lighter

E Air Conditioner Panel

F Engine RPM Dial

G E (Economy) Mode Switch

H H/P (High/Power) Mode Switch

I Key Switch

J Rear Light Switch

K Overload Alarm/Indicator

L Not available on this model

M - Not available on this model

g. Pilot control and shutoff lever

1) The pilot control shut-off lever (A, figure 18A) shuts off hydraulic

pilot pressure to all pilot control valves. When pilot control shut-off


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lever is in locked position, the machine will not move if a lever or pedal is accidentally moved.

2) Always pull pilot control shut-off lever to locked position when you stop the engine or leave the

operators station. Figure 18Ah. Power boost switch

Push power boost switch (A, figure 18B) on top of right control lever for an 8 second, 6% increase inhydraulic power. Release switch to reset power boost function.

9. Controls and Indicators

a. Level check switch

b. Window washer switch

Figure 18Bc. Wiper switch

d. Auto idle switch

1) The auto-idle circuit automatically reduces engine speed after 4 seconds

when control levers are placed in neutral position. Press switch (A) to turn

circuit ON.

2) Starting engine when auto-idle is ON

When key switch is turned ON, buzzer will sound briefly

3) The engine will run at the engine RPM dial setting for 4 seconds after

turning the key switch ON. The auto-idle system will then slow the engineto auto-idle engine speed.

4) Engine speed increases to engine RPM dial setting when any control lever is operated.

5) Four seconds after control levers are returned to neutral, the engine speed is reduced toautomatically to auto-idle level.

6) When the auto-idle switch is turned OFF, the engine speed is controlled by the engine RPM dial.

7) Indicator (B) will light when auto-idle is ON.


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8) Turn auto-idle switch OFF and set engine RPM dial to improve machine control in difficult work

areas, loading, and unloading.

CAUTION: Turn auto-idle switch OFF when automatic acceleration of engine speed is not desired,

and when stopping engine. Always check auto-idle switch before operating any control levers. When

ON, the engine speed lowers to auto-idle speed (regardless of the position of the engine control lever)

approximately 4 seconds after the control levers are returned to neutral. By operating the control

levers, the engine speed increases to the engine RPM dial setting.

e. Travel speed selector switch

f. Buzzer stop switch

g. Work mode selection switch and work mode indicator

1) Select operating modes by pressing the mode selection switch (A). In

each mode, a microcomputer automatically selects the best combination ofengine speed and pump flow rates that fits the working load. The dig

mode (B) is automatically selected when the engine is started.

2) Use the following as a guide:

a) Dig Mode (B) - Designed for general digging and truck loading

b) Grading Mode (C) - Arm roll-in is slower for grading and finishingwork

c) Precision Mode (D) - For work that requires precision front

movement.

d) Attachment Mode (E) - When using attachments other than the bucket.

3) E (Economy) Mode

a) Use E mode to improve fuel efficiency and reduce noise level with a small

difference in engine speed. E mode is effective when the dig mode is

selected as the work mode.

b) Push down E mode switch (A). The switch will stay down and E mode

indicator (B) will light. Push the E mode switch again. The switch willreturn to original position and will deactivate the E mode.


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4) H/P (High Power) Mode

NOTE: With both the H/P and E modes turned on, the digging power increases

while achieving low fuel consumption.

a) Use H/P mode when extra horsepower is needed for rolling in the arm

in excavation work. The H/P mode is effective when the dig mode is

selected as the work mode. H/P mode can also be used with the Emode turned on.

b) The H/P mode will be activated, automatically increasing the enginespeed when:

1) H/P Mode switch (A) is pushed down

2) Engine speed is set to 1600 RPM or higher.

3) Arm roll in is operated.

4) A load heavier than a specified amount is applied.

c) Push down H/P mode switch (A). The switch will stay down and H/P indicator (B) will light.

Push the H/P mode switch again. The switch will return to original position and will deactivate

the H/P mode.

5) Standard Mode

The engine is in standard mode when no switches are pushed down and no indicator lights are on.

h. Light switch

i. High Power (HP), Economy (E), Auto-Idle (AI) indicators

NOTES


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j. Monitor Panel

A Engine Coolant temperature Gauge

B Warm Up Indicator

C Fuel Gauge

D H/P (High/Power) Mode Indicator

E E (Economy) Mode Indicator

F Auto Idle Indicator

G Hydraulic Oil Lever Indicator

H Hydraulic Oil Filter Restriction Indicator (Model

230LCRD)

I Fuel Level Indicator

J Air Filter Restrictor Indicator

K Charge Air Temperature Indicator

L Engine Coolant Temperature Indicator

M Engine Oil Pressure Indicator

N Alternator Voltage Indicator

O Engine Oil Level Indicator

P Engine Coolant Level Indicator

NOTES


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k. Switch Panel

A Level Check Switch

B Attachment Mode Indicator

C Precision Mode Indicator

D Grading Mode Indicator

E Dig Mode Indicator

F Work Mode Switch

G Buzzer Stop Switch

H Propel Speed Switch

I Auto Idle Switch

J Wiper Switch

K Washer Switch

L Operating Lights Switch

l. Instrument panel

1) Coolant indicator

2) Fuel indicator (light activates when tank contains 8 gallons or less)

3) Warning lights

NOTES


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Chapter 2

Hand and Arm Signals

2-1

1. Excavator and backhoe hand signals

a. Boom up: Fist closed, thumb pointing up

b. Boom down: Fist closed, thumb pointing down

c. Arm in: Fist closed, chest high, thumb pointed away from ground guide

d. Arm out: Fist closed, chest high, thumb pointed towards ground guide

e. Open bucket: Open fist, palm forward

f. Close bucket: Closed fist

g. Open thumb: Use thumb and index finger shaped as an "L".

h. Close thumb: Close thumb/index finger together.

i. Swing left: Left index finger pointing towards right hand, palm opened

j. Swing right: Right index finger pointed towards left hand, palm opened

k. Turn right: Left arm extended, pointing away from body with index finger, while holding right hand

chest high in a closed fist

l. Turn left: Right arm extended pointing away from body with index finger, while holding left handchest high in a closed fist

m. Forward right: Left arm extended pointing away from body with index finger, with right hand opened,

palm facing ground guide, motions towards ground guide in a forward movement

n. Forward left: Right arm extended pointing away from body with index finger, with left hand opened,

palm facing ground guide, motions towards ground guide in a forward movement

o. Forward: Both hands opened, palm facing ground guide, motioning towards ground guide in a

forward movement

p. Stop: Right hand in a cutting motion across the waist

q. Park line position: One closed fist on top of hard hat

r. See instructor: Left palm level, right hand forming legs in walking motion

s. Cool down/Kill engine: Right or left hand in a cutting motion across throat


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Chapter 2

Hand and Arm Signals

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t. Travel position: Right hand in a cutting motion across the right knee

CAUTION: Before using hand signals, the equipment operator and signal person must clearlyunderstand the meaning of each signal.

NOTES


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Chapter 3

Safety

3-1

1. Safety Requirements

a. Hard hats will be worn when on or around the equipment.

b. Use three points of contact when climbing in, on or out of the equipment.

c. Remain aware of your surroundings.

d. Wear your seat belt.

e. Sound "FIRE IN THE HOLE" prior to starting the equipment.

f. Sound the horn prior to moving the machine or any attachment.

g. Never back up, swing 180 and move in desired direction.

h. When acting as the ground guide, always maintain eye to eye contact with the operator.

i. If you have a ground guide, remember they are in control. "PAY ATTENTION"

j. At the first sign of lighting, dismount the equipment and find shelter.

CAUTION: Read all warning labels before operating machine.

NOTE: Safety depends on our ability to communicate. Read and familiarize yourself with all safety

labels before operating the machine.

2. Safety Operations

a. Avoid power lines

b. Serious injury or death can result from contact with electrical lines.

c. Never move any part of the machine or load closer to electric lines than

10 feet plus twice the line insulator length.

d. Use your seatbelt.

e. Before moving machine, find out which way to move propel pedals/levers

for the direction you want to go. Pushing down on the front of the propel

pedals or pushing the levers moves the machine towards the idlers.


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Safety

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f. Keep the bucket on the uphill side, approximately 12 inches (A) above the ground, when going up or

down hill. If machine starts to slip or become unstable, lower the bucket immediately.

3. Exhaust Fumes

a. Prevent asphyxiation. Engine exhaust fumes can cause sickness or

death.

b. If you must operate in a building, be positive there is adequate

ventilation. Use an exhaust pipe extension to remove the exhaust fumes

or open doors and windows to bring enough outside air into the area.

4. Operation from operators seat

a. Avoid possible injury or machine damage. DO NOT start engine by

shorting across starter terminals.

b. NEVER start engine while standing on ground. Start engine only from

operators seat.

c. Machines equipped with cabs are equipped with secondary exits. For additional secondary exit

information, see the topics Secondary Exit Tool and Opening Upper Front (Secondary Exit)

Window in chapter 10 of the TM 5-3805-280-10

5. Machine Safety

a. Clear all persons from area of operation and machine movement.

b. Use your seatbelt.

c. Make sure the work site footing has sufficient strength to firmly support the

machine. When working close to an excavation, position machine with propelmotors at the rear.

d. Be cautious of tipping when working on frozen ground. Temperature increase will cause ground tobecome soft, making ground unstable.

e. When digging deep, avoid hitting bottom of boom or bucket cylinder hoses against the ground.

f. Use the bucket only for digging. Do not use it as a jackhammer or wrecking ball.

g. Move & operate machine safely


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Safety

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h. Bystanders can be run over. Know the location of bystanders beforemoving, swinging, or operating the machine.

i. Always keep the traveling alarm in working condition. It warns peoplewhen the machine starts to move.

j. Use signal person when moving, swinging, or operating the machine incongested areas. Coordinate hand signals before starting the machine.

6. Seatbelt Safety

a. Keep seatbelt in good condition.

b. The complete seatbelt assembly should be replaced after 3 years of usage, regardless of appearance.

c. Between replacement intervals:

1) Carefully examine buckle, webbing, and attaching hardware.

2) Be sure that the retractor, if equipped, locks to preventbelt extension after latching buckle.

3) Be sure that attaching hardware is in place. Tighten, if necessary.

4) Replace the seat belt if it does not operate properly or if it is damaged, worn, or deteriorated.

7. Fueling Safety

Handle fuel with care; it is highly flammable. DO NOT refuel the machine while

smoking or when near open flame or sparks. Always stop engine beforerefueling machine. Fill fuel tank outdoors.

Operational Safety

a. Only allow the operator on the machine. Keep riders off.

b. Riders on machine are subject to injury such as being struck by foreign

objects and being thrown off the machine. Riders also obstruct the operators

view resulting in the machine being operated in an unsafe manner.


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Safety

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8. Park Line Safety

a. Park machine on a level surface

b. Lower bucket to the ground

c. Close the thumb to the ground

d. Turn auto-idle switch off.

e. Run engine RPM dial at 1/3 position for 2 minutes.

f. Move engine RPM dial to slow idle position.

g. Allow engine to cool.

h. Turn key switch to OFF. Remove key from switch.

i. Pull pilot control shut-off lever to locked position.

NOTES


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Chapter 4

Operators Preventive Maintenance Checks and Services

4-1

1. Engine oil checks

a. Before the engine is started it is full when the oil is in the crosshatch area. It is acceptable to run the

engine when the oil level is above the add mark.

b. After the engine has been run allow the oil to drain back into the oil pan for 10 minutes before

checking the oil level

c. Remove filler cap and add oil only as necessary

Note: Engine oil is most accurate when engine is cold. The machine must be parked on level ground,

remove the dipstick and wipe it off, put the dipstick back in the tube and reseat it. Remove the

dipstick and check the oil.

2. Coolant System controls the temperature of components within the range of the highest operating

temperature 140-180).

a. The capacity of the radiator is 24 quarts or 6 gallons.

b. It takes a 50/50 mix of water and antifreeze when adding fluid.

c. The normal operating range is 120-130.

d. Cooling System Factors

1) Coolant Level

2) Coolant Condition

3) Thermostats

4) Radiator Condition

5) Belts

6) Fan Air Flow

7) Fan Shroud

8) Water Pump Flow

9) Hose Collapse/Blockage


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10) Air Cleaner Restriction

11) Overloading Engine

12) Temperature Range (Environment)

13) Recovery Tank

e. Cooling System Checks

1) Fluid Level (Check at recovery tank)

2) Recovery Tank (Has Full and Low indicator marks)

3) Leaks (Radiator, Hoses, Recovery Tank)

4) Condition (Radiator Fins, Oil Cooler Fins, Radiator Cap)

5) Radiator Air Inlet Screens (Clean As Needed)

Note: #1 Never add fluid to the radiator unless the recovery tank is completely empty, Always add

fluid to the recovery tank to keep the system at the proper level.

Radiator Cap is a two-stage release, turn cap slowly to first area of detent and release pressure (15

P.S.I.) Then press down and turn cap to open position.

Hot Cooling systems build pressure, always stop engine and let the system cool. Remove cap only after

cool. Check level at recovery tank.

WARNING: Hot pressurized fluids can cause serious burns. DO NOT OPEN RADIATOR WHILE

HOT

3. Fuel System

a. The fuel tank is located on the right side of the excavator.

b. The fuel tank capacity is 82 gallons.

1) Clean the inlet screen as needed and replace if damaged.

2) Drain water and sediment from fuel tank weekly or as needed.

3) Water Separator, use pump to extract water and Dispose of Waste Properly


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4) Fill tank at the end of the day to help avoid condensation.

5) Allow for fuel expansion. Fill no more than 38mm (1.5 in.) below filler neck.

ENVIROMENTAL: Improper disposing of waste can threaten the environment and ecology. DO

NOT pour waste onto the ground, down a drain, or into any water source.

c. Filling the fuel tank

1) Stop engine

2) Shut off electrical equipment

3) Ground fuel nozzle

NOTE: NEVER SMOKE WHILE RE-FUELING AND NEVER CUT OR WELD ON FUEL LINES,

TANKS OR CONTAINERS.

4. Hydraulics

a. The hydraulic tank is located on the right side just behind the fuel tank.

b. Hydraulic pump capacity is 1.1 quarts.

c. Hydraulic tank capacity is 39 gallons.

d. The hydraulic pump is located on the right rear of the excavator.

e. Hydraulic oil type to be used in this machine is 10 W

f. The complete hydraulic system capacity is 71 gallons.

g. Hydraulic System Checks

1) Fluid level (pump dipstick/ hydraulic tank sight gauge)

2) Filter condition (leaks, dents, etc)

3) Oil condition (contamination present?)

4) Leaks (hydraulic pump, hoses, cylinders)

5) Hose condition (torn, worn, damaged)


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6) Fasteners/hardware (bolts tight, all present)

WARNING: Fluids under pressure can penetrate the skin or eyes and cause serious injury, blindness

and death. Always check hoses and clamps with cardboard/ wood, wear face shield or goggles. If anaccident occurs treat immediately.

7) Adding fluid to the hydraulic tank:

a) Park machine on a level surface.

b) Position machine correctly, ensure arm cylinder is fully retracted, bucket fully retracted, andboom is lowered to the ground.

c) Shut down engine in accordance with procedures and allow to system to cool down.

d) Ensure sight gauge (right side rear of hydraulic tank) reads low.

e) Loosen the vent plug (hex nut) SLOWLY to release pressure.

f) Use the 4mm allen wrench to release cap SLOWLY.

g) Once all pressure has been released, turn cap and remove.

h) Carefully fill to required level (avoiding contamination).

i) Replace cap and lock back into place.

Notes________________________________________________________________________________________

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5. Electrical System

a. The battery is located inside the left rear engine compartment.

NOTE: Keep Batteries Clean! Build up of contamination and debris (wet straw or wood) can cause the

charge in the batteries to drain down or catch fire. Batteries produce a fume hazard while charging

and during use.

b. Slave Receptacle 24 volt system

NOTE: Before boost starting, machine must be properly shut down to

prevent unexpected machine movement when engine starts.

CAUTION: An explosive gas is produced while batteries are in use or

being charged. Keep flames or sparks away from the battery area.Make sure the batteries are charged in a well ventilated area.

c. The slave receptacle can be used to charge the batteries and slavestart the engine from an external power source. The slave receptacle

can also be used to charge and slave other equipment.

6. Undercarriage checks:

a. Propel motors oil level

1) There are 3 plugs/ per-motor

2) Fill plug

3) Level check plug

4) Drain plug

5) Oil capacity is 6.4 quarts for each propel motor.

6) The oil type is 80/90W

b. Leaks, (inside & outside edge)

1) Propel motors

2) Sealed track bearings

3) Any oil stains


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c. Excessive/ Unusual Noise

1) Sign of track tension (loose/ tight)

2) Bent/ broken shoes

3) Loose track shoe bolts

4) Bent/ broken step

5) Check overall condition of undercarriage

d. Grease where appropriate

1) Used only to adjust track tension on undercarriage, NOT as a lube point.

e. Steps for checking track sag.

1) Swing upper structure 90 degrees.

2) Lower boom to raise track off the ground.

3) Keep angle (A) between boom and arm at 90 110 degrees.

4) Position the bucket round side on the ground.

5) Place blocks under machine frame to support machine.

6) Rotate track forward two full rotations then in reverse two full rotations.

7) Measure distance through vertical centerline of middle track roller from bottom of track frame to

top surface of track shoe.

8) Track sag specification for normal ground condition is (11 13/16 13 3/16 in.).

9) Repeat steps for both sides.

NOTE: Adjust track sag to the actual operating conditions. Tracks could require adjustment several

times during a day due to changing soil conditions.


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IMPORTANT: Prevent possible damage to track components. DO NOT use the grease fitting on the

track adjustment cylinder for lubrication. Use this fitting ONLY for track adjustment.

A loose track has more side-to-side motion, increasing side wear on the links, rollers and front idler.

An excessively loose track will SLAP at high ground speeds, resulting in high impact loads on the

teeth, bushings and carrier rollers.

7. Track Sag

a. To tighten track, connect a grease gun to grease fitting (A) (located through access hole in trackframe. Add grease until sag is within recommended limits.

CAUTION: Prevent possible injury from high pressure grease. DO NOT remove grease fitting (A)

from nut (B).

b. To loosen track, turn nut (B) counterclockwise: grease

will escape through the bleed hole (C)

Nut Specification

Torque.108 ft-lb

When the track sag is satisfactory, turn nut to clockwise to

tighten.A Grease Fitting

B Nut

C Bleed Hole

8. Wear blocks

Replace wear blocks on each track before they are worn down to the cap screws

Notes________________________________________________________________________________________

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Chapter 5

Maneuvering

5-1

1. Starting and stopping procedures

a. Pre-start checks

1) Check instruments before starting

2) Turn key switch to ON position. All indicator lights will stay on forapproximately 3 seconds.

3) The indicator lights will also stay on for approximately 3 seconds whenthe key switch is turned to START position.

4) If any lamp fails to light, the bulb may be burned out.

5) The fuel gauge will show the fuel level.

6) The coolant gauge should NOT go to the red zone.

b. Level Check

1) Turn key switch to ON position.

2) Press level check switch (A).

3) Hydraulic oil level (B), engine coolant level (C), and engine oil level(D) indicators will light if levels are adequate for operation.

IMPORTANT: The level check does NOT take the place of daily checks at

hydraulic oil level window, engine coolant recovery tank, and engine oil

level dipstick.

c. Starting the engine

IMPORTANT: Before starting the engine in extreme cold, unit must be prepared

with proper grade lubricants.

1) Move engine RPM dial (A) to slow idle position.

IMPORTANT: Prevent starter damage. Never operate starter for more than 30 seconds

at a time. If engine fails to start, return key switch to OFF. Wait for about 2 minutes,then try again. After a false start, do not turn the key again until the engine stops.

2) Sound horn to alert persons nearby.


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3) Turn key switch to START. Release key; switch will return to ON position.

d. Warming the machine

1) Start engine. Run engine at 1/3 speed for 30 seconds. DO NOT run the engine at fast or slowidle. DO NOT accelerate rapidly during warm-up.

2) Operate machine at less-than-normal loads and speeds until the engine is at normal operatingtemperature.

e. Utilizing starting fluid (cold weather starting aid)

CAUTION: Prevent possible injury from exploding container. Starting

fluid is highly flammable. Keep container away from heat, sparks, or open

flame. Contents are pressurized. DO NOT puncture or incineratecontainer from machine if engine does not need starting fluid.

IMPORTANT: Prevent damage to engine. Use starting aid when

temperatures are below 44 degrees F and only A Starting Aid Button

when engine is cold.

1) Move engine RPM dial to the slow idle position.

2) Turn key switch clockwise to the START position.

3) As soon as the engine starts cranking you must depress the starting aid button (A).

IMPORTANT: Excess starting fluid could damage engine; push starting aid button only when engine is coldand cranking. Starting aid fluid is being injected into engine as long as you push switch.

4) If engine is cranking but no cylinders are firing you must crank the engine for a maximum of 30seconds. Then release the starting aid button (A) and turn the key switch to the OFF position.

5) If the engine is cranking and some cylinders are firing, continue cranking and pushing the starting

aid button (A) for a maximum of 50 seconds, or until the engine is running.

Notes________________________________________________________________________________________

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Maneuvering

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f. Replacing Starter Aid Can

1) Remove clamp (B) from container

2) Turn container (C) counterclockwise to remove.

3) Turn container clockwise to install.

IMPORTANT: Protect starting aid components from possible damage.

Install dust cap (D) on the starting valve when cylinder is not installed

in starting valve.

B ClampC Container

D Dust Cap

g. Check instruments after starting

IMPORTANT: Prevent possible damage to engine. If indicator lights

do not go out after starting engine, IMMEDIATELY STOP THE ENGINE. Find and correct the

problem.

h. Cold weather warm up

CAUTION: Prevent possible injury from unexpected machine movement. If hydraulic oil is cold,

hydraulic functions move slowly. DO NOT attempt normal machine operations until hydraulicfunctions move at close-to-normal cycle times.

1) In extreme cold conditions, an extended warm-up period will be necessary. Under such

conditions, the radiator and oil cooler should be covered to maintain correct operating

temperatures.

2) Run engine at speed for 5 minutes. Do not run at fast or slow idle.

CAUTION: Prevent possible injury from unexpected machine movement. Clear the area of all persons

before running your machine through warm-up procedure. If machine is inside a building, warm the

propel circuit first and move the machine to a clear area outside. Cold oil will cause machine functions

to respond slowly.

3) Exercise propel and swing functions slowly, initially moving only short distances.

4) Operate boom, arm, and bucket functions by moving cylinders a short distance each direction for

the first time.


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Chapter 5

Maneuvering

5-4

5) Continue cycling cylinders by increasing the travel each cycle until full stroke is obtained.

6) Swing upper structure so boom is perpendicular to tracks.

CAUTION: Prevent possible injury from machine sliding backwards. Keep angle between boom and

arm 90-110 degrees.

7) Keeping the angle between boom and arm 90-110 degrees, fully actuate bucket close function(cylinder extend) and lower bucket to raise track off ground.

IMPORTANT: Holding function actuated for more than 10 seconds can cause damage from hot spots

in the control valve.

8) While rotating raised track in forward direction, actuate bucket curl function (cylinder extend) for

10 seconds and release for 5 seconds for a period of 2 minutes.

9) Repeat procedure with track rotating in reverse direction.

10) Lower machine to ground.

11) Repeat steps 5-9 on opposite track.

12) Operate all hydraulic functions to distribute warm oil in all cylinders, motors, and lines.

13) If hydraulic functions still move slowly repeat steps 6 and 7.

i. Stopping the engine

IMPORTANT: Prevent possible engine damage. If engine stops when operating under load, remove

load. Restart engine immediately. Run 30 seconds at speed before adding load.

1) Park machine on a level surface.

2) Lower bucket to the ground.

3) Turn auto-idle switch off.

IMPORTANT: Turbocharger may be damaged if engine is not properly shut down.

4) Run engine with engine RPM dial at 1/3 position without load for 2 minutes.

5) Move engine RPM dial to slow idle position.

6) Turn key switch to OFF. Remove key from switch


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Chapter 5

Maneuvering

5-5

7) Pull pilot control shut-off lever to locked position.

2. Maneuvering the 230 LCR Hydraulic Excavator

a. Steering the machine using pedals/levers

CAUTION: Keep bystanders clear of machine when traveling. Before

moving machine, determine which way to press propel pedals.

b. Keep bystanders clear of machine when traveling

c. The instruction below apply when the propel motors (E) are to therear of the machine. If propel motors are to the front of the

machine, the machine moves OPPOSITE the direction described.

1) Forward travel: Push down on front (A) of both pedals.

2) Reverse travel: Push down on rear (C) of both pedals.

3) Neutral position (B): Propel brakes will automatically stopand/or hold the machine.

4) Right turn: Push down on front of left pedal.

5) Left turn: Push down on front of right pedal.

6) Short turn (counter rotate): Push down the front of one pedaland the rear of the other.

IMPORTANT: When traveling over long distances, swing upper

structure so propel motors are positioned to the rear.

7) Long distance travel: When traveling over long distances,

swing upper structure so propel motors are to the rear. Pushdown on pedal tab (D) and rest feet on footrests.

CAUTION: Prevent possible injury from machine tipping. Operate

control pedals slowly when traveling down a slope.

8) Traveling down a slope: Operate control pedals slowly whentraveling down a slope.


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Chapter 5

Maneuvering

5-6

9) Cold Weather Operation: Propel pedal dampers are provided for smooth control. In extremely

cold weather, pedal effort will increase. Operate pedal several times with pilot control shut-offlever in locked position.

d. Propel Speed Switch

1) Fast speed or slow speed travel can be selected in each working mode by

turning the propel speed switch (A).

2) To lower travel speed, such as traveling on a slope or moving in a tight

space, turn switch to slow speed.

e. Travel Alarm & Travel Alarm Cancel Switch

1) The travel alarm sounds when a propel pedal is depressed andwill continue as long as the tracks are moving. When travel

motion stops, the travel alarm switch is reset.

2) After the initial 12 second alarm, alarm can be silenced by

depressing the travel alarm cancel switch (A).

f. Maneuvering the machine on flat ground

1) Use your seat belt

2) Select a route that is as flat as possible. Steer machine asstraight as possible making small, gradual changes in

direction.

3) When driving over rough terrain, reduce speed to lessen

possibility of undercarriage damage. Reduce speed whencarrying a heavy load, or working in a congested area.

4) When possible, avoid obstacles, rough terrain, rocks, curbs, and ditches. In general, decreasespeed to increase control.

5) When driving, carry bucket or attachment low for good visibility and machine stability and toavoid overhead obstacles. Visibility may also be improved by rotating upper structure slightly.

g. Maneuvering the machine on slopes

Use your seatbelt.

CAUTION: Prevent possible injury from machine rollover. DO NOT turn machine on a slope.


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Chapter 5

Maneuvering

5-7

h. Maneuvering the machine down slopes

1) Use your seatbelt.

2) Lower bucket near to ground as shown.

3) Angle of boom to arm should be 90 degrees.

4) Drive down slope with boom on the downhill end of the machine.

5) If machine begins to slide, lower boom, placing bucket against or

in the ground to slow the machine.

i. Maneuvering the machine up slopes

1) Use your seatbelt

2) Position undercarriage so propel motors will be on uphill end of

machine.

3) Keep the bucket on the uphill side, approximately 12 in. (A) above

ground.

4) If machine starts to slip or become unstable, lower the bucket immediately.

j. Maneuvering the machine off an embankment

1) To move machine over edge of embankment, position bucket with

flat surface resting on ground. Angle (A) of arm to boom should be

90 degrees.

2) Bucket must be on ground before machine begins to tip.

IMPORTANT: To prevent machine damage, do not allow machine to impact

ground with bucket absorbing force of the fall.

4) As machine moves forward, raise the boom and retract arm until front

of tracks reaches the lower ground level.

5) Raise bucket off the ground. Rotate upper structure 180 degrees.


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Chapter 5

Maneuvering

5-8

6) Position bucket on ground with flat surface of bucket resting on ground. Angle (A) of arm to

boom should be 90 degrees.

7) Lower boom slightly and propel machine towards lower level as the arm is extended.

8) When tracks clear embankment, raise boom to lower undercarriage on lower ground level.

9) To move machine onto an embankment, reverse procedure.

Notes________________________________________________________________________________________

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Chapter 6

Lifting

6-1

1. Using the Hydraulic Thumb

a. The hydraulic thumb was designed to be used for the following procedures:

1) Clamping and lifting

2) Medium duty scrap handling

3) Demolition of wood and brick structures

4) Medium duty land clearing/grubbing

5) Bulky loose materials

6) Logging

b. DO NOT use the hydraulic thumb for the following procedures:

1) Ripping-up concrete and asphalt

2) Quarry applications

3) Heavy scrap handling

4) Heavy land clearing

5) Heavy grubbing

6) Breaking ledge rock

2. Using the two way hydraulic thumb foot pedal (Model 230LCR)

a. The Model 230LCR machine is equipped with a third foot pedal (A).

This pedal controls the movement of the hydraulic thumb.

b. To close the hydraulic thumb, push down the top of the pedal (B).

c. To open the hydraulic thumb, push down the bottom of the pedal (C).

A-- Foot Pedal

B -- Top of PedalC -- Bottom of Pedal


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Chapter 6

Lifting

6-2

3. Clamping with Bucket

From the stored position actuate and locate the hydraulic thumb near the object to be picked up. Curl-in

the bucket (A) to the point where it begins to grasp and force the object being picked up into the face ofthe hydraulic thumb. The thumb is capable of large clamping forces and could crush the object. Toprevent the bucket and thumb from crushing the object, feather the bucket control to the point where

the object can be picked up but not crushed.

4. Clamping with Hydraulic Thumb

CAUTION: This method is less precise and should only be used where there is no

concern about crushing the object to be clamped.

Retract the hydraulic thumb to the store position (B). This allows better operator

visibility. Position the bucket behind and curl it in until it is near or in contact withthe object being picked up. Actuate the hydraulic thumb and allow it to grasp and

clamp. This method of grasping is usually less precise and objects may be crushed.

5. Lifting Objects

CAUTION: Always use caution when lifting and transporting objects with the

hydraulic thumb and bucket. Excavators can lift heavy objects that are closer to the

excavator.

As heavy objects are moved further away from the machine via boom and arm

actuation, the possibility of making the machine unstable exists. Use caution whenlifting, moving and rotating heavy objects away from the excavators main body.

Never lift clamped objects over people. The possibility always exists that the lifted objects could drop.

6. Releasing Clamped Objects

CAUTION: Always look before you release a clamped load. Never release a clamped load while

moving or turning. Objects clamped in the jaws should be released one of two ways. Retract the

material clamp or retract the bucket.

Notes

________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

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Chapter 7

Attachments

7-1

1. Using Quick-Disconnect Hitch

a. The cylinder in the Quick-Disconnect Hitch is powered by

hydraulic oil from the excavator bucket cylinder, which isdiverted to the Quick-Disconnect by an electric solenoid valve.The switch is located on the left side rear cab glass.

NOTE: The solenoid coil is energized only in the unlatch position.

b. To attach the Quick-Disconnect Hitch to an attachment

manually, lift and rotate the safety lock pin lever on the bucket to rear of the Quick-Disconnect Hitch.Fully extend the bucket cylinder and set the Quick-Disconnect Hitch switch (A) to the latched

position. Extend the bucket cylinder again and place the oil over relief (except for rock drillattachment). This will activate the cylinder to the open position.

c. Operate the excavator to position the Quick-Disconnect Hitch in the

vertical position (B). The attachment must be level and resting on

the ground.

d. Position the Quick-Disconnect Hitch to engage the front hook of the

attachment (C).

e. Rotate the Quick-Disconnect Hitch to seat the rear of latch over the

rear attachment pins (D).

CAUTION: Do not raise the attachment without acceptable wedgeengagement. The attachment can fall causing possible injury to people in

the vicinity of attachment.

f. Move the latch swing to the latch position and move the bucket control

in order to carefully curl the Quick-Disconnect Hitch and theattachment to full extension of the bucket cylinder. This will place oil

over the relief and divert oil to the hydraulic latch cylinder in order to

engage the wedge into the attachment.

NOTE: Keep the attachment close to the ground during all latch and

unlatch operations.

CAUTION: Wedge must be engaged into attachment.


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Chapter 7

Attachments

7-2

IMPORTANT: The safety lock pin is a safety device to mechanically secure

the attachment in the event of hydraulic system failure. The machine should

not be operated without the safety lock pin in the locked position (E).

g. The safety lock pin lever is at the rear of the Quick-Disconnect Hitch.Carefully rotate the spring loaded safety lock pin lever toward the

excavator to engage the lock pin.

2. Quick Disconnect Attachment Removal

a. Fully extend arm and curl bucket in. Place the attachment on the ground.

b. Manually lift and rotate the safety lock pin lever from its locked positionand install it in the unlocked position (F).

c. To unlatch the quick-Disconnect Hitch from an attachment fully extend the

bucket cylinder. Move the Quick-Disconnect Hitch switch (A) in the

operators cab to the unlatched position. Move the bucket control to extend the bucket cylinder againto place hydraulic oil over relief (except rock drill attachment). This will activate the latch cylinder to

the open position.

NOTE: Alarm will sound when switch is in unlocked position.

d. Operate the excavator to rotate the Quick-Disconnect Hitch in the

vertical position.

e. Remove the Quick-Disconnect Hitch from the hook on the front of the

attachment (H).

Notes

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Chapter 8

Ditching

8-1

1. Arm Digging

a. For most general excavating, leveling material, and digging trenches.

b. To begin excavating, position the arm in a vertical position and thenmove it away from machine approximately 2 ft.

c. Extend the dipper arm completely and position the bucket teeth at a30 angle. As the bucket fills, curl the bucket while retracting the arm.

The first cut should be approximately 4 ft long and 3-4 in. deep. Remaining cuts should be

approximately 4 ft long and 4-6 in. deep.

2. Bucket digging for power digging and for working in a small or cramped excavation. Use the bucketcylinder (A) for digging.

a. Lower the bucket to the digging area and use the boom to force the

bucket into the ground. Work two functions at once; retracting the arm,

and curling the bucket until the bucket is full.

b. If the bucket stalls, raise the boom slightly and continue to curl bucket.

c. If arm stalls, roll back bucket to break it out.

IMPORTANT: To avoid damaging cylinder(s), DO NOT strike ground

with bucket or use bucket for tamping when bucket cylinder is fully

extended (bucket completely curled under).

d. When bucket cylinder is fully extended, DO NOT strike the ground withthe bucket or use the bucket for tamping.

e. DO NOT use the bucket as a hammer or pile driver. DO NOT attemptto shift rocks and break walls using swing motion.

f. DO NOT side load bucket. For example, DO NOT swing bucket to

level material or DO NOT strike objects from the side with the bucket.

g. Match bucket, bucket teeth, or attachment to type of material being handled.

h. Loose fragmented material dumps quickly from the bucket. To break up material as it enters the

bucket, excavate materials in thin layers rather than jamming it into the bucket. This is especially

important with sticky materials.


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Chapter 8

Ditching

8-2

i. If you clean the bucket by rapping it against the stop, to prevent cylinder damage, use the MINIMUM

amount of force. Clean the bucket by hand if rapping bucket lightly does not work. DO NOT try toremove material from bucket by striking bucket against the ground or another object.

3. Preventing Cave-ins

a. Work perpendicular to or at an angle to excavation with propel motors

to the rear of the machine.

b. DO NOT drive near the edge of an excavation or trench.

c. DO NOT dig under machine.

4. Planning Spoil Piles

a. To prevent cave-ins, place spoil pile at least 3 ft away from excavation.

The deeper the excavation the further the spoil pile should be placed from

the excavation. Place spoil piles convenient to truck loading or backfilling.

b. On slopes, place spoil pile on the upper side of the slope for improved

machine stability and easier backfilling.

5. Trenching

a. Before starting work, make sure you have a digging permit, walk the site

to uncover hazards and to plan the job. Check for buried utility lines,pipes, and for gas/oil pipelines.

b. To prevent cave-ins, dig a V shaped trench and place spoil piles at least 1

m (3ft) away from trench. The deeper the trench, the further the spoil pile

should be placed from it.

c. If you have to clean up a cave-in and cannot reach it from machines present

position, DO NOT back over the trench. Drive the machine beside thetrench to the cave-in. Park the machine at a 90-degree angle with the propel

motors to the rear of the machine. Clean cave-in from the side of the trench.

d. When trenching across a slope, level the machine so that the bottom of the

trench will be level. Level the machine by counter rotating tracks or by

digging a shelf.

e. Place the spoil pile on the upper side of the trench. The machine is more

stable and backfilling is easier.


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Chapter 8

Ditching

8-3

f. For straight line trenching, drive two stakes in at the beginning of the

trench. Drive the first stake in immediately behind the starting point andthe second stake approximately 30 ft behind the first (A).

g. Use the stakes as a sight gauge. They are especially helpful if the machineis moved often.

6. Backfilling

a. When backfilling, position machine at a 90 degree angle to the excavation,

with propel motors to the rear of the machine.

b. To prevent machine damage, DO NOT use the side of the bucket tobackfill.

c. The bucket side can be used for finish grading.

d. Extra material can be backfilled around foundations to allow for settling.

7. Operating In Water and Mud

a. Be careful not to operate the machine in water or mud above the upper

deck surface of the undercarriage, causing the swing bearing and rotary

manifold to be submerged.

b. If the swing bearing and rotary manifold are submerged, remove coverfrom underneath center of machine. Remove drain plug (A) to drain

water and mud.

c. Clean swing gear area. Install plug and cover. Lubricate swing gear and swing bearing. (see

maintenance chartEvery 500 Hours Chapter.)

8. Clean Track Frame Area

a. Swing upper structure 90 degrees.

CAUTION: Prevent possible injury from machine sliding backwards.

Keep angle between boom and arm 90-110 degrees.

b. Lower bucket (round side down) to raise track off ground, keeping angle

(A) between boom and arm 90-110 degrees.

c. Run track back and forth to remove mud and dirt.


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Chapter 8

Ditching

8-4

d. Turn engine off.

CAUTION: Prevent possible injury from unexpected machine movement. Place blocks under machine

frame to support machine while cleaning track frame area when track is stationary.

e. Place blocks under machine frame. If further cleaning of track frame area is performed while track is

stationary.

f. Clean track often during cold weather to prevent damage to track components.

9. Operating Tips

a. Before starting work, walk the site to uncover hazards and to plan the job. Check for buried utilitylines and pipes and for gas and oil pipelines.

b. Keep site clean and level to maximize machine stability reduce operator fatigue, and increase

productivity.

c. Do not knock down stakes or grade markers. If you lose sight of your guides, you may have to re-

work the job.

Notes________________________________________________________________________________________

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Chapter 9

Loading

9-1

1. Truck Loading

a. The fastest method for loading a haul unit is with the excavator

positioned on a bench or stockpile and the truck positioned below.

b. Level loading area during wait time between trucks to maximize

machine stability, decrease operator fatigue, and increase

productivity.

c. Know location of all persons in working area, including truck driver. DO NOT load the truck unless

the truck driver is in a safe place.

d. If possible, park truck where wind will be behind operator to keep dust of the dumped load out ofoperators eyes and out of engine air cleaner.

e. Raise the bucket while swinging toward the truck.

f. Dump first load into truck from a minimum height to lessen the stress on the truck. The first materialin the box will cushion following loads. Dump the load into truck at a steady pace (rather than

abruptly) to minimize stress on truck.

g. Load truck box from center front to center rear.

h. If loading large rock, first place a load of smaller rock into truck to cushion impact of large rock intruck.

i. Move bucket to excavation level while swinging away from the truck.

j. DO NOT swing the bucket over the cab.

Notes________________________________________________________________________________________

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Appendix A

Performance Evaluation Sheet

A-1

Evaluation Guidance: Score the Soldier GO if all steps are passed (P). Score the Soldier NO-GO if

any step is failed (F). If the Soldier fails any step, retrain and retest them. Retraining will be

conducted outside of the training day.

1st 2nd

PERFORMANCE MEASURES DATE GO NO GO NO GO

PRE-OPERATION PROCEDURESDid the student:

1. Perform a 360 degree walk around

of equipment. _______ ____ ________ ________

2. Perform before operations PMCS. _______ ____ ________ ________

3. Perform pre-start procedures. _______ ____ ________ ________

4. Perform starting procedures. _______ ____ ________ ________

5. Configure HYEX to travel position. _______ ____ ________ ________

AFTER OPERATION PROCEDURES

Did the student:

1. Configure HYEX to park line position. _______ ____ ________ ________

2. Perform stopping procedures. _______ ____ ________ ________

3. Perform after operations PMCS. _______ ____ ________ ________

Evaluators Comments:

________________________________________________________________________________________

________________________________________________________________________________________

________________________________________________________________________________________

Evaluator's Signature:______________________________________________________________



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Appendix A

Performance Evaluation Sheets

A-2




1st 2nd


MANEUVER OPERATIONS

Did the student:

1. Perform pre-operation procedures. _______ ____ ________ ________

2. Maneuver through a predesignated

course. _______ ____ ________ ________

3. Perform after operation procedures. _______ ____ ________ ________


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Appendix A


A-3




1st 2nd


LIFTING OPERATIONSDid the student:


2. Inspect the work area for any hazards. _______ ____ ________ ________

3. Move a load with the hydraulic latch

lifting point. _______ ____ ________ ________

4. Move a load with the hydraulic thumb. _______ ____ ________ ________



_______________________________________________________________________________________

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Appendix A


A-4




1st 2nd


ATTACHMENT REPLACEMENTDid the student:


2. Remove the bucket. _______ ____ ________ ________

3. Attach the bucket. _______ ____ ________ ________



_______________________________________________________________________________________

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Appendix A


A-5




1st 2nd


EXCAVATION OPERATIONSDid the student:


2. Level the excavator. _______ ____ ________ ________

3. Extend dipper arm completely. _______ ____ ________ ________

4. Place the bucket teeth at a 30 angle. _______ ____ ________ ________

5. Make a marking cut approximately

4 long and 3-4 deep. _______ ____ ________ ________

6. Make ditching cuts approximately

4 long and 4-6 deep. _______ ____ ________ ________

7. Maintain full buckets as close to

the ground as possible. _______ ____ ________ ________

8. Place spoil a minimum of 3 feet away

from the trench. _______ ____ ________ ________

9. Repeat the digging cycle until ditchwas 3 deep and 20 long. _______ ____ ________ ________

Evaluators Comments:______________________________________________________________________________

______________________________________________________________________________




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Appendix A


A-6




1st 2nd


LOADING OPERATIONSDid the student:


2. Configure machine for traversing up

a steep slope. _______ ____ ________ ________

3. Traversed up a slope. _______ ____ ________ ________

4. Level the excavator. _______ ____ ________ ________

5. Position the haul unit and operator. _______ ____ ________ ________

6. Raise the bucket while swinging toward

the haul unit. _______ ____ ________ ________

7. Dump loads from minimum height. _______ ____ ________ ________

8. Load the haul unit from center front tocenter rear. _______ ____ ________ ________

9. Load the haul unit without swinging over

the cab. _______ ____ ________ ________

10.Swing bucket back to stock pile while

lowering and leveling the bucket. _______ ____ ________ ________

11.Load the haul unit to struck capacity

without causing equipment damage. _______ ____ ________ ________

12. Traversed down the slope. _______ ____ ________ ________

13.Perform after operation procedures. _______ ____ ________ ________


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Appendix A



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Documents

2006 US Army StudentGuides Hyex Student Guide 56p